Professional Documents
Culture Documents
EQUIPMENTS CONSTRUCTION
Via Parma, 59 42028 POVIGLIO (RE) ITALY
Tel +39 0522 960050 (r.a.) Fax +39 0522 960259
e-mail: zapi@zapispa.it web: www.zapispa.it
EN
User Manual
AC-2 FLASH
INVERTER
The contents of this publication is a ZAPI S.p.A. property; all related authorizations are covered
by Copyright. Any partial or total reproduction is prohibited.
Under no circumstances will Zapi S.p.A. be held responsible to third parties for damage caused
by the improper use of the present publication and of the device/devices described in it.
Zapi spa reserves the right to make changes or improvements to its products at any time and
without notice.
The present publication reflects the characteristics of the product described at the moment of
distribution. The publication therefore does not reflect any changes in the characteristics of the
product as a result of updating.
NOTES LEGEND
4
U
Page - 2/72
Contents
1
2
5
6
INTRODUCTION ...................................................................................................................5
SPECIFICATION ...................................................................................................................6
2.1
Technical specifications..............................................................................................6
2.2
Block diagram .............................................................................................................6
SPECIFICATION FOR THE INPUT DEVICES FILLING UP THE INSTALLATION KIT.......7
3.1
Microswitches .............................................................................................................7
3.2
Accelerator unit...........................................................................................................7
3.3
Other analog control unit ............................................................................................8
3.4
Speed feedback..........................................................................................................8
INSTALLATION HINTS.......................................................................................................10
4.1
Material overview......................................................................................................10
4.1.1
Connection cables ......................................................................................10
4.1.2
Contactors...................................................................................................10
4.1.3
Fuses ..........................................................................................................10
4.2
Installation of the hardware.......................................................................................11
4.2.1
Positioning and cooling of the controller .....................................................11
4.2.2
Wirings: power cables.................................................................................11
4.2.3
Wirings: CAN connections and possible interferences ...............................11
4.2.4
Wirings: I/O connections .............................................................................14
4.2.5
Connection of the encoder..........................................................................14
4.2.6
Main contactor and key connection ............................................................15
4.2.7
Insulation of truck frame..............................................................................15
4.3
Protection and safety features ..................................................................................16
4.3.1
Protection features......................................................................................16
4.3.2
Safety Features...........................................................................................16
4.4
EMC..........................................................................................................................17
4.5
Various suggestions .................................................................................................19
OPERATIONAL FEATURES ..............................................................................................20
5.1
Diagnosis ..................................................................................................................20
DESCRIPTION OF THE CONNECTORS............................................................................22
6.1
Connectors of the logic - Traction configuration .....................................................22
6.2
Connectors of the logic - Pump configuration...........................................................25
6.3
Description of power connections.............................................................................28
DRAWINGS .........................................................................................................................29
7.1
Mechanical drawing ..................................................................................................29
7.2
Connection drawing - Traction configuration ............................................................30
7.3
Connection drawing - Pump configuration................................................................31
7.4
Connection drawing - Combi configuration ...............................................................32
PROGRAMMING & ADJUSTMENTS USING DIGITAL CONSOLE...................................33
8.1
Adjustments via Console ..........................................................................................33
8.2
Description of Console & Connection .......................................................................33
8.3
Description of Standard Console Menu ....................................................................34
8.3.1
Traction configuration .................................................................................34
8.3.2
Pump configuration .....................................................................................35
8.4
Function configuration ..............................................................................................35
8.4.1
Traction .......................................................................................................35
8.4.2
Pump...........................................................................................................39
Page - 3/72
8.5
10
11
12
13
Parameter regulation................................................................................................ 46
8.5.1
Traction....................................................................................................... 46
8.5.2
Pump .......................................................................................................... 47
8.6
Programming console functions ............................................................................... 49
8.7
Sequence for Ac Inverter Traction setting ................................................................ 50
8.8
Sequence for Ac Inverter Pump setting.................................................................... 51
8.9
Tester: description of the function ............................................................................ 51
8.9.1
Traction....................................................................................................... 52
8.9.2
Pump .......................................................................................................... 53
OTHER FUNCTIONS .......................................................................................................... 56
9.1
Description of the Console SAVE function............................................................. 56
9.2
Description of Console RESTORE function ........................................................... 58
9.3
Description of ALARMS menu ............................................................................... 60
9.4
Description of Console PROGRAM VACC function............................................... 61
AC-2 FLASH INVERTER DIAGNOSTIC - TRACTION CONFIGURATION ....................... 63
10.1 Analysis of alarms displayed on console.................................................................. 63
AC-2 FLASH INVERTER DIAGNOSTIC - PUMP CONFIGURATION................................ 67
11.1 Analysis of alarms displayed on console.................................................................. 67
RECOMMENDED SPARE PARTS FOR INVERTER ......................................................... 71
PERIODIC MAINTENANCE TO BE REPEATED AT TIMES INDICATED......................... 72
APPROVAL SIGNS
COMPANY FUNCTION
INITIALS
FF
PROJECT MANAGER
FG
TECHNICAL ELECTRONIC
MANAGER VISA
PP
PN
SIGN
Publication N: ADEZP0DC
Edition: December 2006
Page - 4/72
1 INTRODUCTION
Within the ZAPIMOS family, the AC-2 FLASH inverter is the model suitable for
control of 3.0 kW to 8.0 kW motors. It has been expressly designed for battery
electric traction.
It is fit for electric truck, golf cars, utility cars.
Page - 5/72
2 SPECIFICATION
2.1 Technical specifications
Inverter for AC asynchronous 3-phase motors
Regenerative braking functions
Can-bus interface
Flash memory (256 Kbytes On-Chip Program Memory)
Digital control based upon a microcontroller
Voltage:....................................................................... 24 - 36 - 48 - 72 80 96 V
Maximum current (24 V, 36 V):.................................................. 500 A (RMS) for 3'
Maximum current (36 V, 48 V):.................................................. 450 A (RMS) for 3'
Maximum current (72 V, 80 V): (*) ...................................... 275/400 A (RMS) for 3'
Maximum current (96 V): ........................................................... 250 A (RMS) for 3'
Booster (all version)..........................10% of maximum current for some seconds;
Operating frequency: ......................................................................................8 kHz
External temperature range: .............................................................-30 C 40 C
Maximum inverter temperature (at full power): ............................................... 75 C
Note (*) For the 72/80 V voltage battery two versions are available: with
maximum current provided of 275 A and of 400 A.
Page - 6/72
3.1 Microswitches
-
The microswitches must have a contact resistance lower than 0.1 and a
leakage current lower than 100 A.
When full load connected, the voltage drop between the key switch contacts
must be lower than 0.1 V.
The microswitches send a voltage signal to the microprocessor when a
function request (for ex.: running request) is made.
The Procedure for automatic potentiometer signal acquisition is carried out using
the Console. This enables adjustment of the minimum and maximum useful
signal level (PROGRAM VACC function), in either direction. This function is
unique when it is necessary to compensate for asymmetry with the mechanical
elements associated with the potentiometer, especially relating to the minimum
level.
The sequence of procedure is described in the programming console manual.
ADEZP0DC - AC-2 FLASH INVERTER - User Manual
Page - 7/72
The two graphs show the output voltage from a non-calibrated potentiometer with
respect to the mechanical zero of the control lever. MI and MA indicate the point
where the direction switches close. 0 represents the mechanical zero of the
rotation.
The Left Hand graph shows the relationship of the motor voltage without signal
acquisition being made. The Right Hand Graph shows the same relationship after
signal acquisition of the potentiometer.
Note: The encoder resolution and the motor poles pair (the controller can
handle), is specified in the home page display of the handset showing following
headline:
AC2T2D
ZP1.13
That means:
AC2T= AC-2 traction controller
(AC2P= AC-2 pump controller)
2 = motors poles pair number
D = 128 pulses/rev encoder
Page - 8/72
F = flash
The encoder resolution is given by the last letter in the following list:
A = 32 pulses/rev
B = 64 pulses/rev
C = 80 pulses/rev
D = 128 pulses/rev
Page - 9/72
4 INSTALLATION HINTS
In the description of these installation suggestions you will find some boxes of
different colours, they mean:
4
U
4.1.2 Contactors
The main contactor must be installed. Depending on the setting of a parameter in
the controller (PWM ON MAIN CONT; see chapter 8.4.1, 8.4.2):
- the output which drives the main contactor coil is on/off (the coil is driven with
the full battery voltage).
- the output which drives the main contactor coil is modulated with a PWM at
high frequency (1 kHz). After an initial delay of about 1 sec in which the coil is
driven with the full battery voltage, the PWM reduces the voltage down to
62%.This feature is useful to decrease the power dissipation of the contactor
coil.
4.1.3 Fuses
-
Page - 10/72
Before doing any operation, ensure that the battery is disconnected and
when all the installation is completed start the machine with the drive
wheels raised from the floor to ensure that any installation error do not
compromise safety.
After operation, even with the Key Switch open, the internal capacitors may
remain charged for some time. For safe operation, we recommend that the
battery is disconnected, and a short circuit is made between Battery
Positive and Battery Negative power terminals of the inverter using a
Resistor between 10 ohm and 100 ohm.
CAN stands for Controller Area Network. It is a communication protocol for real
time control applications. CAN operates at data rate of up to 1 Megabits per
second.
Page - 11/72
It was invented by the German company Bosch to be used in the car industry to
permit communication among the various electronic modules of a vehicle,
connected as illustrated in this image:
The best cable for can connections is the twisted pair; if it is necessary to
increase the immunity of the system to disturbances, a good choice would
be to use a cable with a shield connected to the frame of the truck.
Sometimes it is sufficient a simple double wire cable or a duplex cable not
shielded.
In a system like an industrial truck, where power cables carry hundreds of
Ampere, there are voltage drops due to the impedance of the cables, and
that could cause errors on the data transmitted through the can wires. In the
following figures there is an overview of wrong and right layouts of the cables
routing.
Wrong Layout:
R
Can Bus
Power cables
Module
1
Module
2
Module
3
R
Correct Layout:
R
Can Bus
Power cables
Module
1
Module
2
Module
3
R
The chain starts from the BATT post of the controller that works with the
highest current, and the others are connected in a decreasing order of power.
Otherwise, if two controllers are similar in power (for example a traction and a
pump motor controller) and a third module works with less current, the best way
to deal this configuration is to create a common ground point (star configuration).
Correct Layout:
R
Can Bus
Power cables
Module
1
Module
2
Center of the Ground connection
Module
3
R
In this case the power cables starting from the two similar controllers must be as
short as possible. Of course also the diameter of the cable concurs in the voltage
drops described before (higher diameter means lower impedance), so in this last
example the cable between the minus of the Battery and the common ground
point (pointed by the arrow in the image) must be dimensioned taking into
account thermal and voltage drop problems.
Can advantages
The complexity of today systems needs more and more data, signal and
information must flow from a node to another. CAN is the solution to different
Page - 13/72
After crimping the cable, verify that all strands are entrapped in the wire
barrel.
Verify that all the crimped contacts are completely inserted on the connector
cavities.
A cable connected to the wrong pin can lead to short circuits and failure;
so, before turning on the truck for the first time, verify with a multimeter the
continuity between the starting point and the end of a signal wire.
For information about the mating connector pin assignment see the
paragraph description of the connectors.
D4
D5
D6
Page - 14/72
VERY IMPORTANT
It is necessary to specify in the order the type of encoder used, in terms of
power supply, electronic output and n of pulses for revolution, because
the logic unit must be set in the correct way by Zapi.
The connection of the main contactor can be carried out following the
drawing in the figure.
The connection of the battery line switches must be carried out following
ZAPI instructions.
If a mechanical battery line switch is installed, it is necessary that the key
supply to the inverter is open together with power battery line; if not, the
inverter may be damaged if the switch is opened during a regenerative
braking.
An intrinsic protection is present inside the logic when the voltage on the
battery power connection overtakes 40% more than the battery nominal
voltage or if the key is switched off before the battery power line is
disconnected.
Page - 15/72
detects a failure in the "SAFETY" circuit, the microcontroller itself will bring the
machine in a safe status.
Suggested connection of "SAFETY" circuit:
- STANDALONE CONFIGURATION: it is suggested to connect safety input to
the "SEAT" microswitch or to the "DEADMAN" microswitch (it depends on the
application); in this way the machine will be brought to a safe status as soon as
the operator leaves the machine.
- COMBI CONFIGURATION: in this case the pump controller acts as
supervisor, checking the traction controller functionality by the CANBUS. So it is
suggested to connect the "SAFETY" input of traction controller to a dedicated
output of pump controller, so that the pump controller can drive the traction safety
input and open the power line in case of malfunctioning of traction controller.
4.4 EMC
EMC stands for Electromagnetic Compatibility, and it represents the studies and
the tests on the electromagnetic energy generated or received by an electrical
device.
So the analysis works in two directions:
1) The study of the emission problems, the disturbances generated by the
device and the possible countermeasure to prevent the propagation of that
energy; we talk about conduction issues when guiding structures such as
wires and cables are involved, radiated emissions issues when it is studied
the propagation of electromagnetic energy through the open space. In our
case the origin of the disturbances can be found inside the controller with the
switching of the mosfets which are working at high frequency and generate
RF energy, but wires and cables have the key role to propagate the
disturbs because they works as antennas, so a good layout of the cables
and their shielding can solve the majority of the emission problems.
2) The study of the immunity can be divided in two main branches: protection
from electromagnetic fields and from electrostatic discharge.
The electromagnetic immunity concern the susceptibility of the controller
with regard to electromagnetic fields and their influence on the correct work
made by the electronic device.
There are well defined tests which the machine has to be exposed to.
These tests are carried out at determined levels of electromagnetic fields, to
simulate external undesired disturbances and verify the electronic devices
response.
Page - 17/72
3) The second type of immunity, ESD, concerns the prevention of the effects of
electric current due to excessive electric charge stored in an object. In fact,
when a charge is created on a material and it remains there, it becomes an
electrostatic charge; ESD happens when there is a rapid transfer from a
charged object to another. This rapid transfer has, in turn, two important
effects:
A) this rapid charge transfer can determine, by induction, disturbs on the
signal wiring and thus create malfunctions; this effect is particularly
critical in modern machines, with serial communications (canbus)
which are spread everywhere on the truck and which carry critical
information.
B) in the worst case and when the amount of charge is very high, the
discharge process can determine failures in the electronic devices; the
type of failure can vary from an intermittently malfunction to a completely
failure of the electronic device.
IMPORTANT NOTE: it is always much easier and cheaper to avoid ESD from
being generated, than to increase the level of immunity of the electronic devices.
There are different solutions for EMC issues, depending on level of emissions/
immunity required, the type of controller, materials and position of the wires and
electronic components.
1) EMISSIONS. Three ways can be followed to reduce the emissions:
A) SOURCE OF EMISSIONS: finding the main source of disturb and work
on it.
B) SHIELDING: enclosing contactor and controller in a shielded box; using
shielded cables;
C) LAYOUT: a good layout of the cables can minimize the antenna effect;
cables running nearby the truck frame or in iron channels connected to
truck frames is generally a suggested not expensive solution to reduce
the emission level.
2) ELECTROMAGNETIC IMMUNITY. The considerations made for emissions
are valid also for immunity. Additionally, further protection can be achieved
with ferrite beads and bypass capacitors.
3) ELECTROSTATIC IMMUNITY. Three ways can be followed to prevent
damages from ESD:
A) PREVENTION: when handling ESD-sensitive electronic parts, ensure the
operator is grounded; test grounding devices on a daily basis for correct
functioning; this precaution is particularly important during controller
handling in the storing and installation phase.
B) ISOLATION: use anti-static containers when transferring ESD-sensitive
material.
C) GROUNDING: when a complete isolation cannot be achieved, a good
grounding can divert the discharge current trough a safe path; the
frame of a truck can works like a local earth ground, absorbing excess
charge. So it is strongly suggested to connect to truck frame all the
parts of the truck which can be touched by the operator, who is
most of the time the source of ESD.
Page - 18/72
Page - 19/72
5 OPERATIONAL FEATURES
-
Speed control.
Optimum behaviour an a slope due to the speed feedback:
the motor speed follows the accelerator, starting a regenerative braking
if the speed overtakes the speed set-point.
the system can perform an electrical stop on a ramp (the machine is
electrically hold on a slope) for a programmable time (see also chapter
8.4).
Stable speed in every position of the accelerator.
Regenerative release braking based upon deceleration ramps.
Regenerative braking when the accelerator pedal is partially released
(deceleration).
Direction inversion with regenerative braking based upon deceleration ramp.
Regenerative braking and direction inversion without contactors: only the
main contactor is present.
The release braking ramp can be modulated by an analog input, so that a
proportional brake feature is obtained.
Optimum sensitivity at low speeds.
Voltage boost at the start and with overload to obtain more torque (with
current control).
The inverter can drive an electromechanical brake.
Hydraulic steering function:
1) traction inverter
- the traction inverter sends a "hydraulic steering function" request to
the pump inverter on the can-bus line (see also OPTIONS chapter
8.4).
- moreover, if the pump inverter is not present (for ex: tractor
application), the traction inverter can manage an "hydraulic steering
function" by driving a hydro contactor which drive a hydraulic steering
motor (output F9), see also OPTIONS chapter.
2) pump inverter
- the pump inverter manage an "hydraulic steering function". That is, it
drives the pump motor at the programmed speed for the
programmed time.
High efficiency of motor and battery due to high frequency commutations.
Self diagnosis with indication of the fault shown by a flashing led.
Modification of parameters through the programming console.
Internal hour-meter with values that can be displayed on the console.
Memory of the last five alarms with relative hour-meter and temperature
displayed on the console.
Test function within console for checking main parameters.
5.1 Diagnosis
The microcontroller continually monitors the inverter and carries out a diagnostic
procedure on the main functions. The diagnosis is made in 4 points:
1) Diagnosis on key switch closing that checks: watchdog circuit, current sensor,
capacitor charging, phase's voltages, contactor drives, can-bus interface, if the
switch sequence for operation is correct and if the output of accelerator unit is
correct.
2) Standby diagnosis in standby that checks: watchdog circuit, phase's voltages,
Page - 20/72
Page - 21/72
Page - 22/72
A1
PCLRXD
A2
NCLRXD
A3
PCLTXD
A4
NCLTXD
A5
GND
A6
+12
A7
FLASH
A8
FLASH
B1
-BATT
-Batt.
ADEZP0DC - AC-2 FLASH INVERTER - User Manual
B2
MODE
C1
CAN-L
C2
CAN-L-OUT
C3
CAN-H
C4
CAN-H-OUT
D1D6
E1
CPOT
E2
PPOT
E3
NPOT
E4
CM
E5
FORW
E6
BACK
E7
PB
E8
CPOTB
E9
PPOTB
E10
NPOTB
-Batt.
E11
-BATT
-Batt.
E12
BACK. FORW
E13
BACK. BACK
E14
F1
KEY
F2
PLC
F3
PBRAKE
F4
SEAT
F5
SAFETY
Page - 23/72
Page - 24/72
F6
PTHERM
F7
CM
F8
NLC
F9
NBRAKE
F10
SR/HB
F11
GND
-Batt.
F12
NTHERM
-Batt.
A1
PCLRXD
A2
NCLRXD
A3
PCLTXD
A4
NCLTXD
A5
GND
A6
+12
A7
FLASH
A8
FLASH
B1
-BATT
-Batt.
B2
MODE
Page - 25/72
Configuration:
MODE: Open (not connected)
Traction inverter
MODE: Close (connected with B1) Pump inverter.
C1
CAN-L
C2
CAN-L-OUT
C3
CAN-H
C4
CAN-H-OUT
D1D6
Page - 26/72
E1
CPOT
E2
PPOT
E3
NPOT
E4
CM
E5
LIFT ENABLE
E6
1st SPEED
E7
3rd SPEED
E8
AN. IN.
E9
PPOT
E10
-BATT
-Batt.
E11
-BATT
-Batt.
E12
HYDRO REQ.
E13
SR
E14
DIG. IN.
F1
KEY
F2
PAUX
F3
PHYDRO
F4
4th SPEED
F5
SAFETY
F6
PTHERM
F7
CM
F8
NAUX
F9
NHYDRO
F10
2nd SPEED
F11
GND
-Batt.
F12
NTHERM
-Batt.
Page - 27/72
Page - 28/72
-BATT
+BATT
U; V; W
7 DRAWINGS
7.1 Mechanical drawing
Page - 29/72
Page - 30/72
Page - 31/72
Page - 32/72
Page - 33/72
Page - 34/72
Page - 35/72
9) AUX FUNCTION
- ON/OFF: if this option is programmed ON the traction inverter applies
maximum braking and traction torque.
10) ENABLE FUNCTION
- PRESENT: input E14 is managed as accelerator enable input.
- ABSENT: input E14 is managed as exclusive hydro input.
11) CHECK PUMP HYDRO
- ON/OFF: if this option is programmed ON, if the traction inverter
doesnt receive any messages by the pump inverter from the CAN-BUS
line, the "CAN BUS KO" warning appears on the traction and the
maximum speed is reduced down to 10%. The traction also checks via
CAN that there arent alarms on pump. If pump is in alarm, the maximum
speed is reduced down to 10%, but in this case any alarm or warning
appears.
SUBMENU "ADJUSTMENTS"
1) SET POT BRK MIN
It records the minimum value of braking pedal potentiometer when the
braking pedal switch is closed; the procedure is similar to the "Program Vacc"
function (see chapter 9.4). This procedure must be carried out only if the
"Pedal braking" option is programmed as "Analog".
2) SET POT BRK MAX
It records the maximum value of braking pedal potentiometer when the
braking pedal is fully pressed; the procedure is similar to the "Program Vacc"
function (see chapter 9.4). This procedure must be carried out only if the
"Pedal braking" option is programmed as "Analog".
3) SET BATTERY TYPE
It selects the nominal battery voltage.
4) ADJUST BATTERY
Fine adjustment of the battery voltage measured by the controller.
5) THROTTLE 0 ZONE
It establishes a deadband in the accelerator input curve (see also curve
below).
6) THROTTLE X POINT
This parameter changes the characteristic of the accelerator input curve.
7) THROTTLE Y POINT
This parameter changes the characteristic of the accelerator input curve.
VACC MIN and VACC MAX are values programmable by the "Program
Vacc" function.
ADEZP0DC - AC-2 FLASH INVERTER - User Manual
Page - 37/72
8) ADJUSTMENT #04
This parameter determines the motor temperature level at which the Motor
temperature alarm is signalled. The range is from 70 C to 160 C with 10 C
steps. This parameter must be adjusted only if the Set temperature (menu
Set option) parameter is programmed Analog.
9) ADJUSTMENT #03
This parameter isn't used.
10) ADJUSTMENT #02
It adjust the lower level of the battery discharge table.
11) ADJUSTMENT #01
It adjusts the upper level of the battery discharge table.
Page - 38/72
AUX
OUTPUT
BRAKE
BRAKE
HYDRO
CONT.
STOP
ON
RAMP
F9
OUTPUT
ON
OFF
ON
HYDRO
CONT.
OFF
EXCL.
HYDRO
ON
EXCL.
HYDRO
OFF
BEHAVIOUR ON A SLOPE
The truck is electrically hold on a
slope; when the time set by
"auxiliary time" parameter is
elapsed the brake is applied and
the 3-phase bridge is released.
Do not use this combination if
the negative brake is not
installed.
The truck is not electrically hold
on a slope, but comes down
very slowly; when the time set
by "auxiliary time" parameter is
elapsed, the brake is applied
and the 3-phase bridge is
opened. Do not use this
combination if the negative
brake is not installed.
The truck is electrically hold on a
slope; when the time set by
"auxiliary time" parameter is
elapsed, the truck comes down
very slowly, till the flat is
reached.
The truck is not electrically hold
on a slope, but comes down
very slowly till the flat is
reached.
The truck is electrically hold on a
slope; when the time set by
"auxiliary time" parameter is
elapsed, the truck comes down
very slowly, till the flat is
reached.
The truck is not electrically hold
on a slope, but comes down
very slowly till the flat is
reached.
8.4.2 Pump
Using the config menu of the programming console, the user can configure the
following functions.
SUBMENU "SET OPTIONS"
1) HOUR COUNTER
- RUNNING: the counter registers travel time only.
- KEY ON: the counter registers when the "key" switch is closed.
2) BATTERY CHECK
- ON: the battery discharge level check is carried out; when the battery
level reaches 10%, an alarm is signalled and the maximum current is
reduced to the half of the programmed value.
- OFF: the battery discharge level check is carried out but no alarm is
signalled.
ADEZP0DC - AC-2 FLASH INVERTER - User Manual
Page - 39/72
Very important:
In the combi system (pump + traction), the battery discharge calculation for
the complete system is carried out by the traction inverter; the information
about the pump inverter consumption is sent on the can-bus line from the
pump inverter to the traction inverter. So the correct programming for the
"Battery check" option is:
traction inverter: ON
pump inverter: OFF.
3) SET TEMPERATURE
- DIGITAL: a digital (ON/OFF) motor thermal sensor is connected to F6
input.
- ANALOG: an analog motor thermal sensor is connected between F6
and F12 (the curve can be customized on a customer request).
- NONE:
no motor thermal sensor switch is connected.
SUBMENU "ADJUSTMENTS"
1) SET BATTERY TYPE
It selects the nominal battery voltage.
2) ADJUST BATTERY
Fine adjustment of the battery voltage measured by the controller.
3) THROTTLE 0 ZONE
It establishes a deadband in the accelerator input curve (see also curve
below).
4) THROTTLE X POINT
This parameter changes the characteristic of the accelerator input curve.
5) THROTTLE Y POINT
This parameter changes the characteristic of the accelerator input curve.
VACC MIN and VACC MAX are values programmable by the "Program
Vacc" function.
Page - 40/72
6) ADJUSTMENT #04
This parameter determines the motor temperature level at which the Motor
temperature alarm is signalled. The range is from 70 C to 160 C with 10 C
steps. This parameter must be adjusted only if the Set temperature (menu
Set option) parameter is programmed Analog.
7) ADJUSTMENT #03
This parameter isnt used.
8) ADJUSTMENT #02
It adjusts the lower level of the battery discharge table.
9) ADJUSTMENT #01
It adjusts the upper level of the battery discharge table.
Page - 41/72
% ' %
' ' '
CONFIG MENU
SET MODEL
% ' '
' ' '
CONFIG MENU
SET OPTIONS
' % '
' ' '
HOUR COUNTER
RUNNING
% ' '
% ' '
BATTERY CHECK
OFF
' ' %
' ' %
BATTERY CHECK
ON
' % '
' ' '
CONFIG MENU
SET OPTIONS
Page - 42/72
' % '
' ' '
BATTERY TYPE
48V
% ' '
% ' '
TROTTLE 0 ZONE
3%
' ' %
' ' %
TROTTLE 0 ZONE
7%
' % '
' ' '
Page - 43/72
Flow chart showing how to use the SET BATTERY TYPE adjustment.
AC2 ZAPI V0.0
48V 350A 00000
% ' %
' ' '
CONFIG MENU
SET MODEL
% ' '
' ' '
CONFIG MENU
ADJUSTMENTS
' % '
' ' '
' ' %
' ' '
' % '
' ' '
Page - 44/72
% ' %
' ' '
CONFIG MENU
SET MODEL
% ' '
' ' '
CONFIG MENU
ADJUSTMENTS
' % '
' ' '
% ' '
% ' '
ADJUSTMENT BATTERY
82.1V
' ' %
' ' %
ADJUSTMENT BATTERY
84.5V
' ' '
' % '
' % '
' ' '
CONFIG MENU
ADJUSTMENT
' ' '
' % '
Page - 45/72
8.5.1 Traction
The following parameters can be modified:
1) ACC DELAY
It determines the acceleration ramp.
2) RELEASE BRAKING
It controls the deceleration ramp when the travel request is released.
3) INVERSION BRAKING
It controls the deceleration ramp when the direction switch is inverted during
travel.
4) PEDAL BRAKING
It determines the deceleration ramp when the travel request is released and
the brake pedal switch is closed.
5) SPEED LIMIT BRK.
Deceleration ramp when the pedal position is changed but not completely
released.
6) BRAKE CUTBACK
It determines the deceleration ramp when the speed reduction input becomes
active and the motor slow down.
7) MAX SPEED FORW
It determines the maximum speed in forward direction.
8) MAX SPEED BACK
It determines the maximum speed in backward direction.
9) CUTBACK SPEED
Speed reduction when the cutback switch is active.
10) CURVE CUTBACK
It determines the speed reduction in curve (only if the eps is present).
11) FREQUENCY CREEP
Minimum speed when the forward or reverse switch is closed, but the
accelerator is on a minimum position.
12) MAXIMUM CURRENT
This parameter changes the maximum current of the inverter.
13) BACKING SPEED
It determines the speed in inching function.
14) BACKING TIME
It determines the time of the inching function.
15) AUXILIARY TIME
It determines the time that the truck is hold on the ramp if the "stop on ramp"
option is ON.
The following table shows the different values at which the parameters can be
set.
Page - 46/72
PARAMETER
PROGRAMMED LEVEL
UNIT
0
Sec.
2.5
3.0
3.5
4.0
4.5
5.0
5.5
6.0
6.5
7.0
Sec.
5.5
5.0
4.5
4.0
3.5
3.0
2.5
2.0
1.5
1.0
Sec.
5.5
5.0
4.5
4.0
3.5
3.0
2.5
2.0
1.5
1.0
Sec.
5.5
5.0
4.5
4.0
3.5
3.0
2.5
2.0
1.5
1.0
Sec.
8.9
8.3
7.7
7.1
6.6
6.0
5.5
4.9
4.4
3.8
Sec.
5.5
5.0
4.5
4.0
3.5
3.0
2.5
2.0
1.5
1.0
MAX SPEED FW
Hz
65
80
95
110
125
140
155
170
185
200
MAX SPEED BW
Hz
65
80
95
110
125
140
155
170
185
200
CUTBACK SPEED
%Max Sp
10
20
30
40
50
60
70
80
90
100
CURVE CUTBACK
%Max Sp
10
21
33
44
55
66
78
89
100
Hz
0.3
0.6
0.9
1.2
1.5
1.8
2.1
2.4
2.7
3.0
%IMAX
47
53
58
64
70
76
82
88
94
100
BACKING SPEED
Hz
10
12
14
16
18
BACKING TIME
Sec.
0. 2
0.5
1.0
1.4
1.8
2.3
2.7
3.1
3.6
4.0
AUXILIARY TIME
Sec.
1.5
2.0
2.5
3.0
3.5
4.0
4.5
FREQUENCY CREEP
MAXIMUM CURRENT
(*)
(**)
The acceleration time shown is the time from 0 Hz to 100 Hz. This is the
ideal ramp calculated by the software; the real ramp could change as a
function of motor control parameter setting and, obviously, as a function
of the load.
The braking feature is based upon deceleration ramps. The value shown
in the table is the time to decrease the speed from 100 Hz to 0 Hz. This
is the ideal ramps calculated by the software; the real ramp could
change as a function of motor control parameter setting and, obviously,
as a function of the load.
8.5.2 Pump
The following parameters can be modified:
1) ACCELER. DELAY
Acceleration ramp.
2) DECELER. DELAY
Deceleration ramp.
3) MAX SPEED UP
It determines the maximum lifting speed with a potentiometer control.
4) MIN SPEED UP
It determines the minimum lifting speed with a potentiometer control when
the lifting enable switch is closed.
5) CUTBACK SPEED
Speed reduction when the cutback switch is active.
Page - 47/72
PROGRAMMED LEVEL
UNIT
0
Sec.
0.5
0.7
1.0
1.4
1.9
2.5
3.2
4.0
4.8
5.5
Sec.
0.5
0.7
1.0
1.4
1.9
2.5
3.2
4.0
4.8
5.5
MAX SPEED UP
Hz
65
80
95
110
125
140
155
170
185
200
MIN SPEED UP
Hz
25.5
%Max Sp
10
20
30
40
50
60
70
80
90
100
Hz
%IMAX
47
53
58
64
70
76
82
88
94
100
Sec.
0.2
0.4
0.8
1.0
1.5
2.0
3.0
4.0
5.0
CUTBACK SPEED
SPEED FINE (ALL) (***)
MAX CURRENT
AUXILIARY TIME
(*)
(**)
(***)
Page - 48/72
Flow Chart showing how to make Programme changes using Digital Console
fitted with Eprom CK ULTRA.
1) Opening Zapi Display.
MAIN MENU
PARAMETER CHANGE
' % '
' ' '
ACCEL. DELAY
LEVEL = 4
% ' '
% ' '
RELEASE BRAKING
LEVEL = 5
' ' %
' ' %
RELEASE BRAKING
LEVEL = 6
' % '
' ' '
MAIN MENU
PARAMETER CHANGE
Page - 49/72
encoder (Hz)
slip value (Hz)
current rms (A)
temperature (C)
motor temperat. (C)
accelerator (V)
forward switch (ON/OFF)
backward switch (ON/OFF)
enable switch (ON/OFF)
seat switch (ON/OFF)
backing f. (ON/OFF)
backing b. (ON/OFF)
cutback switch (ON/OFF)
brake switch (ON/OFF)
exclusive hydro (ON/OFF)
brakepedal pot. (%)
hand brake (ON/OFF)
voltage booster (%)
battery voltage (V)
battery charge (%)
-
encoder (Hz)
slip value (Hz)
current rms (A)
temperature (C)
motor temperature (C)
accelerator (V)
lifting switch (ON/OFF)
1st speed switch (ON/OFF)
2nd speed switch (ON/OFF)
3rd speed switch (ON/OFF)
4th speed switch (ON/OFF)
hydro speed req. (ON/OFF)
cutback switch (ON/OFF)
voltage booster (%)
battery voltage (V)
battery charge (%)
If the machine is a forklift, check the performance with and without load.
9) RELEASE BRAKING. Operate the machine at full speed. Release the
accelerator pedal. Adjust the level to your requirements. If the machine is a
forklift, check the performance with and without load.
10) INVERSION BRAKING. Operate the machine at 25% full speed. Whilst
travelling INVERT the Direction Switch. Set a soft Level of Inversion Braking.
When satisfactory, operate the machine at Full Speed and repeat. If the
machine is a Forklift, repeat the tests and make adjustments with and without
load. The unlade full speed condition should be the most representative
condition.
11) PEDAL BRAKING (If used). Operate the machine at full Speed. Release the
accelerator pedal and press the Pedal Brake. Set braking level to your
requirements.
12) Set MAX SPEED FORW.
13) Set MAX SPEED BACK (Reverse).
14) Make the choice for the truck behaviour on a slope (see chapter 8.4). If the
"Stop on ramp" option is ON, set the desired value of "auxiliary time"
parameter.
15) Set SET TEMPERATURE, setting the motor thermal sensor type used.
Page - 51/72
the TESTER function of the console. The Console acts as a multimeter able to
read voltage, current and temperature. The following definition listing shows the
relative measurements.
8.9.1 Traction
1) MOTOR VOLTAGE
This is the voltage supplied to the motor by the inverter; it is expressed as a
percentage of the full voltage (which depends of the battery voltage).
2) FREQUENCY
This is the frequency of the voltage and current supplied to the motor.
3) ENCODER
This is the speed of the motor, expressed in the same unit of the frequency;
this information comes from the speed sensor.
4) SLIP VALUE
This is the difference of speed between the rotating field and the shaft of the
motor, expressed in the same unit of the frequency.
5) CURRENT RMS
Root Mean Square value of the motor current.
6) TEMPERATURE
The temperature measured on the aluminium heat sink holding the MOSFET
devices.
7) MOTOR TEMPERAT.
This is the temperature of the motor; if the option is programmed "None" (see
chapter 8.4.1) it shows 0.
8) ACCELERATOR
The voltage of the accelerator potentiometer's wiper (CPOT). The voltage
level is shown on the Left Hand Side of the Console Display and the value in
percentage is shown on the Right Hand Side.
9) FORWARD SWITCH
The level of the Forward direction digital entry FW.
- ON / +VB = active entry of closed switch.
- OFF / GND = non active entry of open switch.
10) BACKWARD SWITCH
The level of the Reverse direction digital entry BW.
- ON / +VB = active entry of closed switch.
- OFF / GND = non active entry of open switch.
11) ENABLE SWITCH
Status of the accelerator enable input.
- ON / +VB = active entry of closed switch.
- OFF / GND = non active entry of open switch.
12) SEAT SWITCH
The level of the Seat Microswitch digital entry.
- ON / +VB = active entry of closed switch.
- OFF / GND = non active entry of open switch.
13) BACKING F.
Status of the inching function (forward direction) input.
- ON / +VB = active entry of closed switch.
- OFF / GND = non active entry of open switch.
14) BACKING B.
Status of the inching function (backward direction) input.
- ON / +VB = active entry of closed switch.
- OFF / GND = non active entry of open switch.
15) CUTBACK SWITCH
The level of the Speed Reduction Microswitch.
- ON / GND = active entry of speed reduction microswitch.
Page - 52/72
8.9.2 Pump
1) MOTOR VOLTAGE
This is the voltage supplied to the motor by the inverter; it is expressed as a
percentage of the full voltage (which depends of the battery voltage).
2) FREQUENCY
This is the frequency of the voltage and current supplied to the motor.
3) ENCODER
This is the speed of the motor, expressed in the same unit of the frequency;
this information comes from the speed sensor.
4) SLIP VALUE
This is the difference of speed between the rotating field and the shaft of the
motor, expressed in the same unit of the frequency.
5) CURRENT RMS
Root Mean Square value of the motor current.
6) TEMPERATURE
The temperature measured on the aluminium heat sink holding the MOSFET
devices.
7) MOTOR TEMPERATURE
This is the temperature of the motor; if the option is programmed "None" (see
chapter 8.4.2) it shows 0.
8) ACCELERATOR
The voltage of the accelerator potentiometer's wiper (CPOT). The voltage
level is shown on the Left Hand Side of the Console Display and the value in
percentage is shown on the Right Hand Side.
9) LIFTING SWITCH
Status of the lifting switch.
- ON / +VB = active entry of closed switch.
- OFF / GND = non active entry of open switch.
10) 1ST SPEED SWITCH
Status of the first speed switch of the pump.
- ON / +VB = active entry of closed switch.
ADEZP0DC - AC-2 FLASH INVERTER - User Manual
Page - 53/72
Page - 54/72
Flow Chart showing how to use the TESTER function of the Digital Console.
1) Opening Zapi Display.
2) Press ENTER to go into the General menu.
3) The Display will show:
4) Press ROLL UP or ROLL DOWN button until
TESTER MENU appear on the display.
5) The Display shows:
' % '
' ' '
MOTOR VOLTAGE
%
% ' '
% ' '
FREQUENCY
Hz
' ' '
' % '
MAIN MENU
TESTER
Remember it is not possible to make any changes using TESTER. All you can do
is measure as if you were using a pre-connected multimeter.
Page - 55/72
9 OTHER FUNCTIONS
9.1 Description of the Console SAVE function
The SAVE function allows the operator to transmit the Parameter values and
Configuration data of the inverter into the Console memory. It is possible to load
64 different programmes.
The information saved in the Console memory can then be reloaded into another
inverter using the RESTORE function.
The data that is available via the SAVE function is as follows:
- All Parameter Values (PARAMETER CHANGE).
- Options (SET. OPTIONS).
- The Level of the Battery (ADJUST BATTERY).
Flow Chart showing how to use the SAVE function of the Digital Console.
AC2 ZAPI V0.0
48V 350A 00000
' % '
' ' '
MAIN MENU
PARAMETER CHANGE
% ' '
% ' '
MAIN MENU
SAVE PARAM.
' % '
' ' '
SELECT: MOD. 00
FREE
% ' '
% ' '
SELECT: MOD. 01
FREE
Page - 56/72
' % '
' ' '
READING
ACCEL. DELAY (ECC.)
MAIN MENU
SAVE PARAM
Page - 57/72
' % '
' ' '
MAIN MENU
PARAMETER CHANGE
% ' '
% ' '
MAIN MENU
RESTORE PARAM.
' % '
' ' '
SELECT : MOD. 00
AC2 ZAPI V1
% ' '
% ' '
SELECT : MOD. 01
AC2 ZAPI V1
Page - 58/72
' % '
' ' '
ARE YOU SURE?
YES=ENTER NO=OUT
' % '
' ' '
12) You can see the items that are being stored in
the inverter memory whilst the RESTORE routine is
happening.
STORING
ACCELER. DELAY
MAIN MENU
RESTORE PARAM.
Page - 59/72
' % '
' ' '
MAIN MENU
PARAMETER CHANGE
% ' '
% ' '
MAIN MENU
ALARMS
' % '
' ' '
CODE
% ' '
% ' '
CODE
CLEAR LOGBOOK?
YES=ENTER NO=OUT
' % '
' ' '
Page - 60/72
This function looks for and remembers the minimum and maximum potentiometer
wiper voltage over the full mechanical range of the pedal. It enables
compensation for non symmetry of the mechanical system between directions.
The operation is performed by operating the pedal after entering the PROGRAM
VACC function.
Flow Chart showing how to use the PROGRAM VACC function of the Digital
Console.
1) Opening Zapi Display.
2) Press ENTER to go into the General Menu.
3) The Display will show:
4) Press ROLL UP or ROLL DOWN button until
PROGRAM VACC appears on the display.
5) The Display will show:
6) Press ENTER to go into the PROGRAM VACC
routine.
7) The Display will show the minimum and
maximum values of potentiometer wiper output.
Both directions can be shown.
ADEZP0DC - AC-2 FLASH INVERTER - User Manual
Page - 61/72
' % '
' ' '
MIN
0.0
VACC
-
MAX
0.0
MIN
0.6
VACC
MAX
4.4
Page - 62/72
2 blinks:
3 blinks:
4 blinks:
5 blinks:
6 blinks:
7 blinks:
8 blinks:
long blink:
no blink:
Page - 63/72
4) LOGIC FAILURE #2
Fault in the hardware section of the logic board which manages the phase' s
voltage feedback. Replace the logic board.
5) LOGIC FAILURE #3
Fault in the hardware section of the logic board which manages the hardware
current protection. Replace the logic board.
6) CHECK UP NEEDED
This is a warning. It is an information for the user that the programmed time
for maintenance is elapsed.
7) INCORRECT START
This alarm signals an incorrect starting sequence. Possible causes:
A) running microswitch failure;
B) error in sequence made by the operator;
C) incorrect wiring;
D) if the default persists, replace the logic.
8) FORW + BACK
The test is carried out continuously. An alarm is signalled when a double
running request is made simultaneously. Possible causes:
A) defective wiring;
B) running microswitch failure;
C) incorrect operation;
D) if the defect persists, replace the logic.
9) HANDBRAKE
The truck does not start because the handbrake switch is opened. Possible
causes:
A) defective wiring;
B) failure of the microswitch;
C) incorrect operation of the operator;
D) if the defect persist, replace the logic.
10) ENCODER ERROR
Two consecutive readings of the encoder speed are too much different in
between: because of the inertia of the system it is not possible the encoder
changes its speed a lot in a short period. Probably an encoder failure has
occurred (e.g. one or two channels of the encoder are corrupted or
disconnected). Check both the electric and the mechanical encoder
functionality. Also the electromagnetic noise on the sensor bearing can be a
cause for the alarm.
11) CAPACITOR CHARGE
Follows the charging capacitor system:
When the key is switched ON, the inverter tries to charge the capacitor
through a power resistance, and check if the capacitor are charged within a
timeout. If this is not true: an alarm is signalled; the main contactor is not
closed.
Possible reasons:
Page - 64/72
12)
13)
14)
15)
16)
17)
18)
Page - 65/72
19)
20)
21)
22)
23)
24)
25)
26)
27)
28)
29)
Page - 66/72
CONTACTOR CLOSED
The controller checks if the LC contact is closed when the coil isnt
driven, trying to discharge the capacitor bank. If they dont discharge, the
fault condition is entered. It is suggested to check the contactor contact, if
it is mechanically stuck or pasted.
AUX OUTPUT KO
The P checks the driver of the electromechanical brake. If the status of the
driver output does not correspond to the signal coming from the P, the
alarm is signalled. Replace the logic.
HIGH TEMPERATURE
Inverter temperature is greater than 75 C. The maximum current is reduced
proportionally to the temperature increase. The inverter stops at 100 C.
If the alarm is signalled when the inverter is cold:
A) check the wiring of the thermal sensor;
B) thermal sensor failure;
C) logic failure.
MOTOR TEMPERATURE
This warning is signalled if the motor temperature switch opens (digital
sensor) or if the analog signal overtakes the cut off level. If it happens when
the motor is cold, check the wiring. If all is ok, replace the logic board.
THERMIC SENSOR KO
The range of inverter temperature sensor is always checked and a warning is
signalled if it is out of range.
When this alarm is signalled, check the connection of the sensors.
MOT. TH. SENSOR KO
The range of motor temperature sensor is always checked and a warning is
signalled if it is out of range.
When this alarm is signalled, check the connection of the sensors.
CAN BUS KO
The diagnosis of the CAN-BUS line is present only if the inverter uses this
link (depends on the software version). It is signalled if the inverter does not
receive any message from the CAN-BUS line. First of all, check the wiring. If
it is ok, the problem is on the logic board, which must be replaced.
SAFETY
This alarm is signalled when the "SAFETY" input is open. The "SAFETY"
circuit gets active and opens the drivers of LC and EB and stops the
machine. Verify the SAFETY input connection.
SAFETY KO
This alarm is present in combi systems (traction + pump). If a stopping alarm
is detected on the pump, the traction also stops. The failure must be looked
for in the pump inverter.
BATTERY LOW
If the "battery check" option is ON, a battery discharge algorithm is carried
out. When the charge level is 10%, this alarm is signalled and the current is
reduced to the half of the programmed level.
WRONG SET BATT.
When the key is turned ON, the controller check the battery voltage and
verifies it is within a window around the nominal value. Replace the battery
with a correct battery.
WAITING FOR NODE
The controller receives from a remote module via CAN Bus the information
that it isnt possible to close the LC (the module isnt ready locked in an alarm
state). Verify the other modules to determinate in which of them there is the
problem.
2 blinks:
3 blinks:
4 blinks:
5 blinks:
6 blinks:
7 blinks:
8 blinks:
long blink:
no blink:
Page - 67/72
4) LOGIC FAILURE #2
Fault in the hardware section of the logic board which manages the phase' s
voltage feedback. Replace the logic board.
5) LOGIC FAILURE #3
Fault in the hardware section of the logic board which manages the hardware
current protection. Replace the logic board.
6) INCORRECT START
This alarm signals an incorrect starting sequence. Possible causes:
A) running microswitch failure;
B) error in sequence made by the operator;
C) incorrect wiring;
D) if the default persists, replace the logic.
7) ENCODER ERROR
Two consecutive readings of the encoder speed are too much different in
between: because of the inertia of the system it is not possible the encoder
changes its speed a lot in a short period. Probably an encoder failure has
occurred (e.g. one or two channels of the encoder are corrupted or
disconnected). Check both the electric and the mechanical encoder
functionality. Also the electromagnetic noise on the sensor bearing can be a
cause for the alarm.
8) CAPACITOR CHARGE
Follows the charging capacitor system:
When the key is switched ON, the inverter tries to charge the capacitors
through a power resistance and check if the capacitors are charged within a
timeout. If this is not true: an alarm is signalled; the main contactor is not
closed.
Possible reasons:
A) check if the charging resistance is opened.
B) The charging circuit has a failure.
C) There is a problem on the power modules.
9) VMN LOW, VMN HIGH
The test is carried out during initial diagnosis and in standby.
Possible causes:
A) problem with the motor connections or the motor power circuit; check if
the 3 phases are correctly connected; check if there's a dispersion of the
motor towards ground;
B) inverter failure, replace it.
10) PEDAL WIRE KO
This alarm is signalled if a fault is detected in the accelerator wiring (NPOT or
PPOT cable is interrupted).
11) VACC NOT OK
The test is made in standby. This alarm indicates that the accelerator voltage
is 1 V greater than the minimum value programmed by the PROGRAM
VACC function.
Page - 68/72
12)
13)
14)
15)
16)
17)
Possible causes:
A) the potentiometer is not correctly calibrated;
B) the potentiometer is defective.
STBY I HIGH
Test carried out in standby. Check if the current is 0. If not verified, an alarm
is signalled which inhibits machine operations. Possible causes:
A) current sensor failure;
B) logic failure: first replace the logic; if the defect persists, replace the
power unit.
SEAT KO
This alarm is present in combi systems (traction + pump). The pump
compares the status of the seat input with the value transmitted by the
traction via CAN-BUS. The alarm is signalled if the two values are different in
between.
DATA ACQUISITION
This alarm is signalled in the current gain acquisition phase. Wait the end of
the acquisition activity.
MAIN CONTACTOR ALARMS
In the combi system (pump + traction) the main contactor is driven by the
traction inverter. So the following description concerns the pump inverter
used independently from the traction inverter. In this configuration the pump
inverter manages its own main contactor.
- COIL SHORTED
When the key is switched ON the P checks the MC driver FF SR. If it
does not react in a correct way to the P stimulus, the alarm is signalled.
Replace the logic board. The FF SR makes an hardware control of the
current in the MC coil. If this is too high, it opens the MC and the alarm is
signalled.
Check if there are external shortcircuit and if the ohmic value of the MC is
correct; otherwise replace the logic.
- DRIVER SHORTED
When the key is switched ON, the P checks that the MC coil driver is
not shorted; if it is, this alarm is signalled; replace the logic board.
- CONTACTOR DRIVER
When the initial diagnosis is finished, the traction logic closes the MC and
checks the voltage on the Drain of the driver. If this is not low, an alarm is
signalled.
Replace the logic.
- CONTACTOR OPEN
The main contactor coil has been driven by the logic board, but the
contactor does not close. Two possible reasons:
A)
the wires to the coil are interrupted or not well connected.
B)
the contact of the contactor is not properly working.
AUX OUTPUT KO
The P checks the driver of the electromechanical brake. If the status of the
driver output does not correspond to the signal coming from the P, the
alarm is signalled. Replace the logic.
HIGH TEMPERATURE
Inverter temperature is greater than 75 C. The maximum current is reduced
proportionally to the temperature increase. The inverter stops at 100 C.
If the alarm is signalled when the inverter is cold:
A) check the wiring of the thermal sensor;
B) thermal sensor failure;
C) logic failure.
Page - 69/72
Page - 70/72
Description
C16507
C16505
C16520
C29523
C29522
C29508
C12442
C12358
C12359
C12407
C12403
C12777
Page - 71/72
13 PERIODIC MAINTENANCE TO BE
REPEATED AT TIMES INDICATED
Check the wear and condition of the Contactors moving and fixed contacts.
Electrical Contacts should be checked every 3 months.
Check the Foot pedal or Tiller microswitch. Using a suitable test meter, confirm
that there is no electrical resistance between the contacts by measuring the volt
drop between the terminals. Switches should operate with a firm click sound.
Microswitches should be checked every 3 months.
Check the Battery cables, cables to the inverter, and cables to the motor. Ensure
the insulation is sound and the connections are tight.
Cables should be checked every 3 months.
Check the mechanical operation of the pedal or tiller. Are the return springs ok.
Do the potentiometers wind up to their full or programmed level.
Check every 3 months.
Check the mechanical operation of the Contactor(s). Moving contacts should be
free to move without restriction.
Check every 3 months.
Checks should be carried out by qualified personnel and any replacement parts
used should be original. Beware of NON ORIGINAL PARTS.
The installation of this electronic controller should be made according to the
diagrams included in this Manual. Any variations or special requirements should
be made after consulting a Zapi Agent. The supplier is not responsible for any
problem that arises from wiring methods that differ from information included in
this Manual.
During periodic checks, if a technician finds any situation that could cause
damage or compromise safety, the matter should be bought to the attention of a
Zapi Agent immediately. The Agent will then take the decision regarding
operational safety of the machine.
Remember that Battery Powered Machines feel no pain.
NEVER USE A VEHICLE WITH A FAULTY ELECTRONIC CONTROLLER.
Page - 72/72